EP3511095A1 - Système de régulation de température pour fabrication additive et procédé associé - Google Patents

Système de régulation de température pour fabrication additive et procédé associé Download PDF

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Publication number
EP3511095A1
EP3511095A1 EP19151391.0A EP19151391A EP3511095A1 EP 3511095 A1 EP3511095 A1 EP 3511095A1 EP 19151391 A EP19151391 A EP 19151391A EP 3511095 A1 EP3511095 A1 EP 3511095A1
Authority
EP
European Patent Office
Prior art keywords
forging
temperature
micro
cladding layer
energy source
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19151391.0A
Other languages
German (de)
English (en)
Inventor
Yong Wu
Yingna Wu
Zirong Zhai
Hai Chang
Yifeng Wang
Yimin Zhan
Dalong Zhong
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP3511095A1 publication Critical patent/EP3511095A1/fr
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J7/00—Hammers; Forging machines with hammers or die jaws acting by impact
    • B21J7/20—Drives for hammers; Transmission means therefor
    • B21J7/22—Drives for hammers; Transmission means therefor for power hammers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • B23K26/034—Observing the temperature of the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0626—Energy control of the laser beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/10—Auxiliary heating means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1051—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by electric discharge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B22F2003/175—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging by hot forging, below sintering temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to the field of additive manufacturing technology, and in particular to a temperature control system for additive manufacturing and method for same.
  • Additive manufacturing technology is a rapidly evolving emerging technology for material processing.
  • the mainstream additive manufacturing usually achieves metallurgical bonding of metal materials through the "melting-solidification" method, which is characterized by using a high-energy beam such as a laser beam, an electron beam or an arc beam as a heat source to melt the synchronously fed metal material, such as metal powder, metal wire, and so on, which are stacked in layers, whereby parts are manufactured by surfacing, and the internal microstructure of the obtained parts is a solidified structure.
  • a high-energy beam such as a laser beam, an electron beam or an arc beam
  • the solidified structure obtained by the above-mentioned "melting-solidification” method produces crystals that are very coarse with obvious directionality, therefore in a general sense, it is difficult to achieve comprehensive performance comparable to that of a forged material.
  • a method of combining the molten deposition additive with thermomechanical processing has been gradually developed, that is, material deposition and metallurgical bonding are achieved by melting-solidification, thereafter rolling, shock processing and other treatments are used to refine the grains and improve internal quality.
  • embodiments of the present invention relate to a temperature control system for additive manufacturing comprising a cladding device, a micro-forging device, a detecting device, a control module, and an adjusting module.
  • a cladding device configured to fuse the material and form a cladding layer, the cladding device comprising a first energy source configured to direct an energy beam toward the material for fusing at least a portion of the material to form the cladding layer.
  • a micro-forging device coupled to the cladding device for forging the cladding layer.
  • a detecting device configured to detect a first internal effect parameter of the cladding layer at a forging position where it is forged by the micro-forging device.
  • a control module configured to receive the first internal effect parameter detected by the detecting device, and calculate a first calculated temperature at the forging position based on the first internal effect parameter.
  • An adjusting module coupled to at least one of the first energy source and the micro-forging device and configured to receive the first calculated temperature and to adjust at least one of the first energy source and the micro-forging device to make the first calculated temperature at the forging position fall within a desired temperature range if the first calculated temperature does not fall within the desired temperature range.
  • embodiments of the invention relate to a temperature control method for additive manufacturing.
  • the method comprises: directing an energy beam of a first energy source toward a material and fusing at least a portion of the material to form a cladding layer; forging the cladding layer with a micro-forging device; detecting a first internal effect parameter of the cladding layer at a forging position where it is forged by the micro-forging device; calculating a first calculated temperature of the cladding layer at the forging position based on the first internal effect parameter; and adjusting at least one of the first energy source and the micro-forging device if the first calculated temperature does not fall within a desired temperature range.
  • embodiments of the invention relate to a temperature control method for additive manufacturing.
  • the method comprises the following steps:
  • Embodiments of the present invention relate to a temperature control system for additive manufacturing, comprising a cladding device, a micro-forging device, a detecting device, a control module, and an adjusting module.
  • the cladding device is configured to fuse the material and form a cladding layer
  • the cladding device comprising a first energy source configured to direct an energy beam toward the material for fusing at least a portion of the material to form the cladding layer.
  • the micro-forging device is coupled to the cladding device for forging the cladding layer.
  • the detecting device is configured to detect a first internal effect parameter of the cladding layer at a forging position where it is forged by the micro-forging device.
  • the control module is configured to receive the first internal effect parameter detected by the detecting device, and calculate a first calculated temperature at the forging position based on the first internal effect parameter.
  • the adjusting module coupled to at least one of the first energy source and the micro-forging device and configured to receive the first calculated temperature and to adjust at least one of the first energy source and the micro-forging device to make the first calculated temperature at the forging position fall within a desired temperature range if the first calculated temperature does not fall within the desired temperature range.
  • FIG. 1 shows a schematic diagram of a temperature control system 100 for additive manufacturing according to one embodiment of the present invention.
  • the temperature control system 100 comprises an additive manufacturing device 110 and a control module 120.
  • the additive manufacturing apparatus 110 comprises a cladding device 117, a micro-forging device 115, and a detecting device 116.
  • the cladding device 117 is configured to fuse the material and form a cladding layer 140 on the platform 130, specifically comprising a first energy source 111 and a material conveyor 113.
  • a material conveyor 113 is configured to feed material 114 to the platform 130 or the cladding layer 140.
  • the first energy source 111 is configured to provide an energy beam 112; when the material 114 is sent to the platform 130 or the cladding layer 140, the first energy beam 112 is directed toward and fusing the material 114, and the molten material rapidly solidifies to form a portion of the cladding layer 140 and becomes part of the object being formed.
  • the micro-forging device 115 is coupled to the cladding device 117 and moves in synchronization with the cladding device 117 to forge the formed cladding layer 140 online and in real time, after the material conveyor 113 of the cladding device 117.
  • the detecting device 116 is configured to detect a first internal effect parameter of the cladding layer 140 at a forging position where it is forged by the micro-forging device 115.
  • the control module 120 comprises a storage unit 121 stored therein a first internal-effect-parameter versus temperature curve of the material 114, the control module 120 receives the first internal effect parameter detected by the detection module 116, calculating the first calculated temperature at the forging position based on the first internal effect parameter and the first internal-effect-parameter versus temperature curve.
  • the first internal-effect-parameter versus temperature curve is an empirical model curve fitted based on existing experimental data.
  • the control module 120 further comprises an adjusting module 150 coupled to at least one of the first energy source 111 and the micro-forging device 115, receiving the first calculated temperature calculated by the control module 120; if the first calculated temperature at the forging position does not fall within the desired temperature range, the first calculated temperature at the forging position is made to fall within a desired temperature range required for material forging by adjusting at least one of the first energy source 111 and the micro-forging device 115, with the desired temperature range, the nature of the material 114 itself, and the distance between the forging position and the molten pool in which the material 114 is melted being related.
  • the adjusting module 150 may be independent from the control module 120, e.g., mounted to the cladding device 117.
  • the first energy source 111 can be any device or device capable of providing an energy beam suitable for additive manufacturing.
  • the energy beam include, but are not limited to, a laser beam, an electron beam, a plasma beam, and an arc beam.
  • the material 114 is typically delivered in the form of a powder or wire (e.g., metal powder, wire, etc.).
  • the material conveyor 113 may comprise a powder feeding nozzle for conveying the powder material, or a wire feeding device for conveying the wire.
  • the material conveyor 113 comprises a powder feeding nozzle or wire feeding device that is coaxial with the energy beam. For example, in the embodiment illustrated in FIG.
  • the material conveyed by material conveyor 113 is in powder form, and comprises a powder feeding nozzle 118 that is coaxial with the energy beam 112.
  • the material conveyed by the material conveyor 113 may be in the form of a wire, and the material conveyor 113 may comprise a wire feeding device that is coaxial with the energy beam 112.
  • the detecting device 116 is further configured to detect a second internal effect parameter of the cladding layer 140 at the forging position forged by the micro-forging device 115, and the storage unit 121 further stores a second internal-effect-parameter versus temperature curve of the material 114. Wherein, if the first calculated temperature at the forging position falls within the desired temperature range, the control module 150 calculates the second calculated temperature at the forging position based on the second internal effect parameter and the second internal-effect-parameter versus temperature curve stored by the storage unit 121.
  • the second calculated temperature does not within the desired temperature range, there may be an error in at least one of the first internal-effect-parameter versus temperature curve and the second internal-effect-parameter versus temperature curve that needs to be corrected; in an unconstrained embodiment, the first internal-effect-parameter versus temperature curve and/or the second internal-effect-parameter versus temperature curve may be updated based on an adaptive algorithm. After the update, the adjusting module 150 performs an adjustment such that the adjusted first calculated temperature and the second calculated temperature fall within the desired temperature range.
  • the adaptive algorithm is an adaptive proportional-integral-derivative (PID) algorithm.
  • the internal effect parameter may be the force of the cladding layer under the action of the micro-forging device or the effect produced by the force, including but not limited to stress and strain.
  • the micro-forging device 115 is mounted on the material conveyor 113 of the cladding device 117; the detecting device 116 is mounted above the material conveyor 113, for detecting at least one of the stress and the strain of the cladding layer 140 at the forging position forged by the micro-forging device 115.
  • the mounting location of the detecting device 116 is not limited thereto, e.g., it may be coupled to other locations of the cladding device 117 or integrated into the control module 120.
  • the detecting device integrated into the control module 120 can detect or collect an axial load of a main axis of the cladding device 117 applied by the micro-forging device, and determine a stress of the cladding layer 140 at the forging position based on the axial load, and transmit it to the control module 120.
  • FIG. 2 shows a schematic diagram of a temperature control system 200 for additive manufacturing according to another embodiment of the present invention.
  • the temperature control system 200 comprises an additive manufacturing device 210 and a control module 220.
  • the additive manufacturing device 210 comprises a cladding device 217, a micro-forging device 215, and a detecting device 216.
  • the cladding device 217 comprises a first energy source 211 and a material conveyor 213 for providing an energy beam 212.
  • the micro-forging device 215 is mounted to a material conveyor 213 of the cladding device 217; the micro-forging device 215 comprises a forging hammer 219 configured to forge the cladding layer 240 through vibration.
  • the detecting device 216 is a distance sensor configured to detect an amplitude of the micro-forging device 215 that is forging the cladding layer 240, and determine a strain of the cladding layer 240 at the forging position based on the amplitude.
  • the control module 220 comprises an adjusting module 250 and a storage unit 221, the storage unit 221 stored therein a strain versus temperature curve of the material 214, and the control module 220 is configured to calculate the first calculated temperature at the forging position based on the strain and the strain versus temperature curve.
  • the detecting device 216 is a stress detecting module for detecting an axial load of a main axis of the cladding device 217 applied by the micro-forging device, and determine a stress of the cladding layer 240 at the forging position based on the axial load. While the storage unit 221 stores the stress versus temperature curve of the material 214, and the control module 220 calculates the first calculated temperature at the forging position based on the stress and the stress versus temperature curve at the forging position.
  • the adjusting module 250 is coupled to at least one of the first energy source 211 and the micro-forging device 215, receiving the first calculated temperature calculated by the control module 220; if the first calculated temperature at the forging position does not fall within the desired temperature range, the first calculated temperature at the forging position is made to fall within a desired temperature range required for material forging by adjusting at least one of the first energy source 211 and the micro-forging device 215, with the desired temperature range, the nature of the material 214 itself, and the distance between the forging position and the molten pool in which the material 214 is melted being related.
  • the adjusting module 250 may be independent from the control module 220, e.g., mounted to the cladding device 217.
  • the cladding device 217 and the detecting device 216 are connected by a certain connecting mechanism 260.
  • the arrangement of the connecting mechanism 260 enables the relative motion and synergy between the cladding device 217 and the detecting device 216.
  • the connecting mechanism 260 comprises, but is not limited to, a linkage, a bracket, a slide, and so on.
  • FIG. 3 shows a schematic diagram of a temperature control system 300 for additive manufacturing according to yet another embodiment of the present invention.
  • the temperature control system 300 comprises an additive manufacturing device 310 and a control module 320.
  • the additive manufacturing device 310 comprises a cladding device 317, a micro-forging device 315, a distance sensor 326, and a stress detecting module 336.
  • the cladding device 317 comprises a first energy source 311 and a material conveyor 313.
  • the micro-forging device 315 is mounted to a material conveyor 313 of the cladding device 317, the micro-forging device 315 comprises a forging hammer 319 configured to forge the cladding layer 340 through vibration.
  • the distance sensor 326 is configured to detect an amplitude of the micro-forging device 315 that is forging the cladding layer 340, and determine a strain at the forging position based on the amplitude.
  • the control module 320 comprises an adjusting module 350 and a storage unit 321, the storage unit 321 stored therein a strain versus temperature curve of the material 314, and the control module 320 is configured to calculate the first calculated temperature at the forging position based on the strain and the strain versus temperature curve.
  • the adjusting module 350 is coupled to at least one of the first energy source 311 and the micro-forging device 315, receiving the first calculated temperature calculated by the control module 320; if the first calculated temperature at the forging position does not fall within the desired temperature range, the first calculated temperature at the forging position is made to fall within a desired temperature range required for material forging by adjusting at least one of the first energy source 311 and the micro-forging device 315.
  • the stress detecting module 336 is configured to detect an axial load of a main axis of the cladding device 317 applied by the micro-forging device 315, and determine an adjusted stress at the forging position based on the load.
  • the storage unit 321 stores the stress versus temperature curve of the material 314, and the control module 320 calculates a second calculated temperature at the forging position based on the adjusted stress and stress versus temperature curve at the forging position.
  • the strain versus temperature curve and/or the stress versus temperature curve may be updated based on an adaptive algorithm.
  • the adjusting module 350 performs an adjustment such that the adjusted first calculated temperature and the second calculated temperature fall within the desired temperature range.
  • the strain parameter detected by the distance sensor 326 is used to adjust the first calculated temperature
  • the stress parameter detected by the stress detecting module 336 is used to correct the adjusted first calculated temperature.
  • the stress parameter detected by the stress detection module 336 is used to adjust the first calculated temperature
  • the strain parameter detected by the distance sensor 326 is used to correct the adjusted first calculated temperature
  • FIG. 4 shows a schematic diagram of a temperature control system 400 for additive manufacturing according to yet another embodiment of the present invention.
  • the temperature control system 400 comprises an additive manufacturing device 410 and a control module 420.
  • the additive manufacturing device 410 comprises a cladding device 417, a micro-forging device 415, and a detecting device 416;
  • the control module 420 comprises an adjusting module 450 and a storage unit 421.
  • the cladding device 417 comprises a first energy source 411 and a material conveyor 413 for providing an energy beam 412.
  • the cladding device 417 and the micro-forging device 415 are connected by a certain connecting mechanism 470.
  • the arrangement of the connecting mechanism 470 enables relative motion and synergy between the cladding device 417 and the micro-forging device 415.
  • the connecting mechanism 470 comprises, but is not limited to, a linkage, a bracket, a slide, and so on.
  • the micro-forging device 415 comprises a forging hammer 419 configured to forge the cladding layer 440 through vibration.
  • the additive manufacturing device 410 is widely applicable to various materials for additive manufacturing, and is particularly suitable for high-temperature alloy materials such as nickel-based and cobalt-based alloys, whose mechanical properties are not substantially degraded in a use environment below 650 °C.
  • the cladding device 417 and the detecting device 416 are connected by a certain connecting mechanism 460.
  • the arrangement of the connecting mechanism 460 enables the relative motion and synergy between the cladding device 417 and the detecting device 416.
  • the connecting mechanism 460 comprises, but is not limited to, a linkage, a bracket, a slide, and so on.
  • the temperature control system 400 further comprises a second energy source 480, wherein the energy beam is directed toward the forging position of the cladding layer 440 in order to increase the temperature of the forging position.
  • the second energy source is selected from one or more of a laser energy source, an electron beam energy source, a plasma energy source, an infrared energy source, an electromagnetic induction energy source, and a resistance energy source.
  • the second energy source 480 may be mounted at any location as would be apparent to those of ordinary skill in the art including, but not limited to, between the cladding device 417 and the micro-forging device 415, and on top of the micro-forging device 415 away from the cladding device 417.
  • the adjusting module 450 further enables the adjustment of the first energy source 411, the micro-forging device 415, the second energy source 480, and other devices in the system, including but not limited to: adjustment of the relative position of the micro-forging device 415, adjustment of the energy output of the first energy source 411 and/or the second energy source 480.
  • FIG. 5 is a flow chart of a temperature control method 500 for additive manufacturing according to an embodiment of the present invention.
  • the method 500 comprises the following steps:
  • the desired temperature range is related to the nature of the material itself and the distance between the forging position and the molten pool where the material is melted.
  • FIG. 6 is a graph showing the relationship between the surface temperature of a material and its distance from the molten pool in one embodiment of the present invention.
  • an Inconel 718 alloy is selected for additive manufacturing, and the Inconel 718 alloy is a precipitation hardened nickel-chromium-iron alloy containing bismuth and molybdenum.
  • the desired temperature range for forging is 980 °C to 1,100 °C.
  • the Inconel718 alloy is forged within this temperature range, and the obtained product has a good surface morphology and stable internal mechanical properties.
  • the surface temperature of the Inconel 718 alloy material does not change much as its distance from the molten pool changes.
  • the advantage of this is that, on the one hand, even if its distance of the hammer head of the micro-forging device from the molten pool is changed due to the up and down vibration, the forging effect is not affected by too great a change in temperature, thereby improving forging stability.
  • the measured internal effect parameters will not become unstable due to the temperature changing too fast with the distance from the molten pool, thereby making it impossible to accurately calculate the temperature at the forging position, and improving the accuracy of temperature control.
  • Step 540 may comprise the following sub-steps:
  • the first internal effect parameter is strain.
  • FIG. 7 shows an internal effect parameter and temperature relationship model suitable for the material shown in FIG. 6 , wherein the dotted line represents the strain versus temperature curve.
  • the detection module determines the strain at the forging position by detecting the amplitude of the micro-forging device acting on the cladding layer.
  • the control module receives the strain parameter, and calculates a first calculated temperature at the forging position using the strain and the strain versus temperature curve shown in FIG. 7 .
  • the first calculated temperature falls within the desired temperature range for forging (980 °C to 1,100 °C)
  • the additive manufacturing reaction continues.
  • the first calculated temperature at the forging position does not fall within a desired temperature range
  • the first calculated temperature at the forging position is made to fall within a desired temperature range by adjusting at least one of the first energy source and the micro-forging device.
  • the adjusting module 450 increases the output energy/power of the first energy source 411 and/or the second energy source 480, such that the adjusted first calculated temperature falls within the desired temperature range for forging.
  • the ratio of energy adjustment is determined by the first calculated temperature, the desired temperature range for forging, and the energy-source-output-temperature versus output-power model.
  • the micro-forging device 415 may be moved relative to the cladding device 417 through a coupling mechanism 470, for adjusting the distance between the micro-forging device 415 and the molten pool whereby the material 414 is melted.
  • the micro-forging device 415 is adjusted to move closer to the molten pool to the adjusted forging position in a direction, such that the first calculated temperature of the adjusted forging position falls within a desired temperature range.
  • the first calculated temperature at the forging position can therefore be adjusted through adjusting a combination of the micro-forging device and the first or second energy source.
  • the adjusting module 450 decreases the output energy/power of the first energy source 411 and/or the second energy source 480, such that the adjusted first calculated temperature falls within the desired temperature range for forging.
  • the micro-forging device when the first calculated temperature at the forging position is greater than the maximum value of the desired temperature range, the micro-forging device is adjusted to move away from the molten pool to the adjusted forging position, such that the first calculated temperature of the adjusted forging position falls within the desired temperature range.
  • the first internal effect parameter is stress.
  • the specific steps are similar to the temperature control method for detecting strain, and their description will not be repeated herein.
  • the method 500 further comprises the following steps:
  • the control module receives the stress parameter and calculates a second calculated temperature at the forging position using the stress and the stress versus temperature curve shown in FIG. 7 .
  • the second calculated temperature falls within the desired temperature range of forging (980 °C to 1,100 °C)
  • the additive manufacturing reaction continues according to the adjustment of Step 550.
  • the strain versus temperature curve and/or stress versus temperature curve may be updated based on the adaptive algorithm.
  • the adjusting module performs adjustment so that the adjusted first calculated temperature and the second calculated temperature fall within the desired temperature range.
  • FIG. 8 is a flow chart of a temperature control method 800 for additive manufacturing according to an embodiment of the present invention.
  • the method 800 comprises the following steps:

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